Archive for August, 2014

Monday, Labor Day 2014 we are set to embark on yet another new adventure at Maize Valley. If you enjoy Craft Beer please come and join us for our Grand Opening of Maize Valley Craft Brewery. But WAIT there is more!

We will be tapping a Cask of Stout too! What does that mean, I asked Jake our Brewmaster and here is a description:

Cask Beer is a traditional method of conditioning and carbonating ale before the advent of pressurized forced carbonation.

A modern Cask

After primary fermentation, ale is transformed to it’s serving vessel with the addition of priming sugar or unfermented sweet wort. The residual yeast still suspended in the beer eats the sugar and CO2 stays in the beer solution.

Permeable plug used to release excess pressure before tapping

Casks were traditionally kept in tavern cellars to keep the cool and pumped up to the bar with a beer engine. Cask Beer is a living beer that changes over time.

Tap that will be pounded into the Cask

It takes a skilled cellarman to ensure the quality of the ale at time of serving. If done right, it should produce an ale that has a creamy head and soft carbonation.

Our "Itty'Bitty" bright or carbonation tanks

Above are our “Itty-Bitty” carbonation tanks. Starting out we are not even a Micro-Brewery but rather what they call a Nano-Brewery. But that is okay we want to learn how to crawl and then see how the walking goes.

Well maybe we need to change this Blogs name? It is hard for us to get across the marketing message that is Maize Valley. We span a lot of different things.

Here we grow again

Briefly “Maize Valley Farm” was began by Kay and Donna (Rohor) Vaughan my wife Michelle’s parents in the 1960’s. Kay’s ancestors were the third settler’s in the township dating back to the 1800’s. Donna’s parents moved into Marlboro township in the early 1900’s. After graduating from Kent State Kay and Donna were married and started the farm and family. They taught school and farmed as many as 6,000 acres. The farm included grain crops and dairy with their son Steve as well as other livestock over the years.

Michelle lower left, Breanne upper left, Donna upper right and Brett

In the late 90’s the farm changed again selling the cows and some equipment and adding a produce market and agri-tourism venture including pumpkin picking and a corn maze. As houses closed in more in 2005 a winery was added and now in 2014 a craft brewery is set to open on Labor Day, September 1st 2014. Today we still farm about 600 acres, with a wide variety of crops ranging from garlic to green beans to grapes to pumpkins and hops.

Harvest 2014

Todd Vaughan is the wine maker and overseeing the beer production with the help of brewmaster Jake Turner. Michelle (Vaughan) Bakan manages the market and food service with the help of main staffer Scott Mann and a whole host of great employees. Bill Bakan is the Fun TSAR in charge of most all outside operations from grounds maintenance to all things “Corn Maze” and such.

Marlboro Madness our Pumpkin Cannon

Stay tuned as we work at using this blog to give “The Rest of the Story” of what goes on and how we try and manage folks expectations. We hope we do well for you. Thanks for stopping by.

In past blog posts have talked about what we do to get the corn growing in the field that we use to create a corn maze. Now it is time to bring the field to life you might say!

Our 2013 Corn Maze Aireal Photograph

The above photograph is of our 2013 “LoCo-Motion” corn maze adventure. Each year we theme our mazes to reflect an idea we think our guests will find enjoyable. Inside the maze are games and activities to do that reflect the designs theme. We have done NASCAR, the BIG FOOT monster truck, the Pony Express and more over the past 13 years. At first we cut the designs by “hand” with flags and grid paper. Later we hired it done by a professional maze carver. Two years ago we purchased our own Global Positioning Satellite guided system to guide us as we cut the corn. Yes we plant the corn first as discussed in a previous blog post, then we carve the design into a solid field of corn.

Maze design in file form on computor

The above pic shows what we start with. We hire a graphic artist to design a cool design and put it into a share able file that we can load onto software on a laptop that we connect to a specially designed GPS system. The the design for 2014 features a Sea Turtle and the trivia games in the maze will be Sea Turtle related as well.

The 2014 Design displayed on my laptop

The GPS system is very accurate so you need a machine that is very maneuverable to take advantage of the detail in the designs. We do what we call “Art Mazes” for a reason.

Commercial Toro Zero Turn Mower with GPS system mounted

You could say you cannot tell what the maze looks like when you are in it and you are mostly correct. But we do more we wrap a whole game and experience around the maze and the photo needs to reflect that. We take pictures and hang them on the walls of our winery/brewery for people to look at all year long, people love to stop and stare and take in that we can actually take the design and actually transfer it to the field so well.

Path right after cutting

The above photo shows what the paths look like right after we cut them. We do not stop there. About two to three weeks later we go over the entire design with a roto-tiller to kill any remaining corn, grind up the cut off stalks and level the paths better for strollers and power or wheel chairs.

Paths after roto-tilling

The above photo shows the paths after roto-tilling. In order to get the proper look to the design we sometimes take our wider sections of corn. The below pic is what it looks like before we hit it with the tiller.

Now we wait till a few weeks before opening day to come back in and set the games and activities portion of the corn maze. It usually takes about an hour to complete the game sheet and find the various trivia questions and other things to follow along with if the guest choose to do so. The corn maze at one time was all we were about along with picking pumpkins. Over the years we have evolved into a unique fall harvest destination with a winery and new for 2014 we will be one of Ohio’s newest craft breweries also.

Since the fall harvest season makes up a huge part of who we are and what we do we spend some time talking about it. People ask us many questions about how we create some the designs. From a produce market and pumpkin patch with a corn maze we have grown into a winery and now a craft brewery. This summer’s weather has been very challenging. In fact we got about another 2-3 inches of rain again last night.

Sweet Corn field

This blog post about our Ohio Corn Maze shows how we actually plant the corn. We are “old school” by modern agriculture standards in the sense our planter is about twenty years old but it gets the job done.

John Deere 7200 Corn Planter

The corn planter plants six rows at a time each row is 30 inches apart. Our planter can plant No-Till or conventional where you till or work the soil from plow to field cultivator as discussed in past posts. Click here for tillage information Our planter is a vacuum planter.

Seed box for an individual row

What that means is we use the tractors hydraulic pump to run a air vacuum pump like on a floor sweeper that draws the individual seeds against a depression with a small hole in it positioned around the rim of a circular planter “plate”.

Seed box removed, black disk top of photo is the plate.

One bag of seed plants about 3 acres.

Bag of seed corn

Seed corn in planter seed box. We “drop” or plant, between 24,000 to 35,000 seeds per acre (an acre is approximately the area of a football field) depending upon the type of corn, and the end use. For corn mazes I shoot for the low end because we plant the field twice at a right angles to each pass.

Seed corn in planter seed box

A individual planter “Plate”. Plates come in different sizes depending upon crop and seed size to be planted. The larger the seed the larger the “cup” in the plate, you also adjust your vacuum if the seed is heavier to hold it in place as it travels around the until it is dislodged by the brush.

Planter plate below seed box

A chain drive turns the plate and as it rotates once a revolution it comes in contact with a brush that pushes it away from the plate.

Chain drive

The seed travels down a tube and into the soil where another part of the planter creates a trench and then closes it after the seed is deposited. Row wipes lead the way directly in front of the seed disk openers. Which are located under the above mentioned planter boxes.

Row wipes are mostly used for No Till planting

A Fertilizer Disk opener is positioned two inches to the side of the seed opener and a depth of two inches below the seed. “2 Down and 2 Over it is called. This helps to ensure the fertilizer is where the plant needs it when it needs it and is not wasted.

Fertilizer Disk opener

A closing wheel travels last closing the seed trench to ensure good soil to seed contact.

Closing wheel

When planting you try a drive as straight as possible, it is a matter of pride and it also helps to maximize field area and yield. Our planter uses old style row markers. An arm extends from the side of the planter towards the side of the field yet to be planted. At the end of the arm is a disk that leaves a small trench that you line up the center of the tractor on. Today’s modern planters use a Global positioning satellite system to do this. Many tractors have this tied into their steering systems such that the computer/satellite actually drives the tractor.

Row marker trench you follow

The difference when you plant a corn maze field vs. a normal field is you make a second pass at a 90 degree angle to your first pass thereby creating a grid. This makes for a denser field of corn with great vegetation coverage which makes for a better corn maze experience.

View looking back toward planter from tractor seat.

If you have good weather and soil temperatures are good your corn should emerge in about seven to ten days.

Corn coming up in rows!

We wait now about five to six weeks to start the maze carving process where we carve the corn maze design into the field from a solid field of corn. We like to have the corn be large enough a mower will kill the majority of it but not too tall to make cutting difficult.

Cutting the paths that make up a corn maze design

Coming soon the “nuts and bolts” of how we create those crazy Maize Valley Ohio Corn Maze designs!